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Briggs & Stratton 700 DOV AC Series Service Manual 273521
Briggs & Stratton 700 DOV AC Series Service Manual 273521
www.ThePowerPortal.com (Dealers)
BRIGGSandSTRATTON.COM (Consumers)
This manual was written to assist engine technicians and service personnel with the repair and
maintenance procedures for Briggs & Stratton engines. It assumes that persons using this manual have
been properly trained in and are familiar with the servicing procedures for these products, including the
proper use of required tools and safety equipment and the application of appropriate safety practices.
Persons untrained or unfamiliar with these procedures or products should not attempt to perform such
work.
Proper maintenance and repair is important to safe, reliable operation of all engines and engine-driven
systems. The troubleshooting, testing, maintenance, and repair procedures described in this manual are
appropriate for the Briggs & Stratton engines described herein. Alternative methods or procedures may
pose risk to personal safety and the safety and/or reliability of the engine and are not endorsed or
recommended by Briggs & Stratton.
All information, illustrations, and specifications contained in this manual were based on the data available
at the time of publication. Briggs & Stratton Corporation reserves the right to change, alter, or otherwise
improve the product or the product manuals at any time without prior notice.
Briggs & Stratton offers two complementary publications to enhance understanding of engine technology,
maintenance, and repair. (Neither publication, however, is a substitution for a recognized training program
for engine technicians.)
• For consumers, Small Engine Care & Repair (p/n 274041) provides a comprehensive overview of how
small air-cooled engines work, basic troubleshooting, and step-by-step maintenance procedures.
• For engine technicians and consumers alike, an in-depth study of engine theory and operation can be
found in the textbook Small Engines (p/n CE8020).
• MODEL 090600
• MODEL 100600
• MODEL 100800
SAFETY INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
ENGINE MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
OIL CHANGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
AIR FILTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1
SPARK PLUG - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
CHARGING BATTERY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
•
Check fuel lines, tank, cap, and fittings frequently for cracks
or leaks. Replace if necessary.
If fuel spills, wait until it evaporates before starting engine.
1
related accessories contain chemicals known When starting engine:
to the State of California to cause cancer, birth • Make sure spark plug, muffler, fuel cap, and air cleaner are
in place.
defects, or other reproductive harm. Wash • Do not crank engine with spark plug removed.
hands after handling. • If fuel spills, wait until it evaporates before starting engine.
• If engine floods, set choke (if equipped) to OPEN/RUN posi-
tion. Place throttle (if equipped) in FAST and crank until
engine starts.
When operating equipment:
WARNING • Do not tip engine or equipment at an angle which would
cause fuel to spill.
Briggs & Stratton does not approve or autho- • Do not choke carburetor to stop engine.
• Never start or run the engine with the air cleaner assembly
rize the use of these engines on 3-wheel All (if equipped) or the air filter (if equipped) removed.
Terrain Vehicles (ATVs), motor bikes, fun/rec- When changing oil:
• If you drain the oil from the top oil fill tube, the fuel tank must
reational go-karts, aircraft products, or vehi- be empty or fuel can leak out and result in a fire or explosion.
cles intended for use in competitive events. When transporting equipment:
• Transport with fuel tank empty or with fuel shut-off valve set
Use of these engines in such applications to OFF.
could result in property damage, serious injury When storing gasoline or equipment with fuel in the tank:
• Store away from furnaces, stoves, water heaters, or other
(including paralysis), or even death. appliances that have a pilot light or other ignition source
because they can ignite gasoline vapors.
WARNING
WARNING
The engine exhaust from this product contains
chemicals known the State of California to Running engines produce heat. Engine
parts, especially mufflers, become
cause cancer, birth defects, and other repro-
extremely hot.
ductive harm.
Severe thermal burns can occur on
contact.
Combustible debris, such as leaves,
grass, brush, etc. can catch fire.
• Allow muffler, engine cylinder fins, and radiator
to cool before touching.
• Remove accumulated debris from muffler area
and cylinder fins.
• It is a violation of California Public Resource
Code, Section 4442, to use or operate the
engine on any forest-covered, brush-covered,
or grass-covered land unless the exhaust sys-
tem is equipped with a spark arrester, as
defined in Section 4442, maintained in effective
working order. Other States and Federal juris-
dictions may have similar laws. Contact the
original equipment manufacturer, retailer, or
dealer to obtain a spark arrester designed for
the exhaust system installed on this engine.
1 WARNING
Before performing adjustments or repairs:
• Disconnect spark plug wire and keep it away Kerosene and its vapors are extremely
from spark plug. flammable and should be handled with the
• Disconnect the negative (-) battery terminal. same precautions as gasoline.
1 When testing for spark:
• Use approved spark plug tester.
• Do not check for spark with spark plug WARNING
removed.
Damaged, worn, or loose fuel compo-
nents can leak fuel. Explosion or fire
WARNING could result.
Engines give off carbon monoxide, an • All fuel components should be in good condi-
odorless, colorless, poison gas. tion and properly maintained.
Breathing carbon monoxide can cause • Repairs should only be made with factory
nausea, fainting, or death. approved parts.
• Start and run engine outdoors. • Repair work should be done by a qualified
• Do not start or run engine in an enclosed area, technician.
even if doors and windows are open. • Flexible supply lines should be checked regu-
larly to make sure they are in good condition.
WARNING
WARNING
Starting engine creates sparking.
Sparking can ignite nearby flammable Rapid retraction of starter cord (kick-
gases. back) will pull hand and arm toward
Explosion and fire could result. engine faster than you can let go.
• If there is a natural or LP gas leak in the area, Broken bones, fractures, bruises, or
do not start engine. sprains could result.
• Do not use pressurized starting fluids because • When starting engine, pull the starter cord
vapors are flammable. slowly until resistance is felt and then pull rap-
idly to avoid kickback.
• Remove all external equipment/engine loads
WARNING before starting engine.
• Direct-coupled equipment components, such
Rotating parts can contact or entangle as but not limited to blades, impellers, pulleys,
hands, feet, hair, clothing, or accesso- and sprockets, must be securely attached.
ries.
Traumatic amputation or severe lacera-
tions can result.
• Operate equipment with guards in place.
• Keep hands and feet away from rotating parts. WARNING
• Tie up long hair and remove jewelry.
• Do not wear loose-fitting clothing, dangling Prolonged or repeated contact with used
drawstrings, or items that could become entan- motor oil could cause injury.
gled in the equipment. • Used motor oil has been shown to cause skin
cancer in certain laboratory animals.
• Thoroughly wash exposed areas with soap and
water.
Fuel and Oil Recommendations viscosity for the outdoor temperature range
expected.
Fuel must meet these requirements:
• Clean, fresh, unleaded gasoline.
• A minimum of 87 octane / 87 AKI
(90 RON). 1
• Gasoline with up to 10% ethanol
(gasahol) or up to 15% MTBE (methyl
tertiary butyl ether) is acceptable.
NOTICE: Do not use unapproved gasoline, such
as E85. Do not mix oil in gasoline or modify the
1
engine to run on alternate fuels. This will damage
the engine components and void the engine
warranty.
To protect the fuel system from gum formation,
mix a fuel stabilizer into the fuel. All fuel is not the
same. If starting or performance problems occur, Figure 1 - 1
change fuel providers or change brands. This
engine is certified to operate on gasoline. The MAINTENANCE CHART
emissions control system for this engine is EM
(Engine Modifications). First 5 Hours
High Altitude • Change oil
At altitudes over 5,000 feet (1524 meters), a
minimum 85 octane / 85 AKI (89 RON) gasoline Every 8 Hours or Daily
is acceptable. To remain emissions compliant,
• Check engine oil level
high altitude adjustment is required. Operation
without this adjustment will cause decreased • Clean area around muffler and
performance, increased fuel consumption, and controls
increased emissions. • Clean finger guard
Operation of the engine at altitudes below 2,500
feet (762 meters) with the high altitude kit is not Every 25 Hours or Annually
recommended. • Clean air filter*
Fresh Start® Fuel Cap • Clean pre-cleaner*
Some engines are equipped with a Fresh Start® Every 50 Hours or Annually
fuel cap. The Fresh Start fuel cap is designed to
hold a cartridge (sold separately) that contains • Change engine oil
fuel stabilizer. • Check muffler and spark arrester
Oil must meet these requirements: Annually
• Briggs & Stratton Warranty Certified oils
are recommended for best performance. • Replace air filter
• Other high-quality detergent oils are • Replace pre-cleaner
acceptable if classified for service SF, • Replace spark plug
SG, SH, SJ or higher.
• Replace fuel filter
• Do not use special additives.
• Clean air cooling system*
Outdoor temperatures determine the proper oil * In dusty conditions or when airborne debris is
viscosity for the engine. present, clean more often.
Use the chart (Figure 1-1) to select the best
Figure 1 - 2
Air Filter
A correctly serviced air filter protects internal
engine parts from airborne dirt and dust. Poor Spark Plug
filter maintenance will allow dirt and dust to be
drawn into the engine, causing wear to the intake The spark plug should be replaced every year.
system and contamination of the oil. Dirt in the oil
forms an abrasive mixture which wears down
moving parts.
NOTICE
1
Figure 1 - 4
Charging Battery
1. Clean the battery of all dirt and corrosion.
2. Clean, then lightly grease the terminals.
Figure 1 - 3
3. Bring the battery to full charge using a
5. Re-install spark plug and torque to values taper charge (automatically reduces
listed in Section 12 - Engine charge rate).
Specifications.
6. Connect spark plug wire. NOTE: Do not exceed a charge rate of 1/10
ampere for every ampere of battery rating.
Consult the battery manufacturer for maximum
charge recommendations.
Cooling System
NOTE: If the battery gets hot to the touch or is
WARNING spitting acid (gassing) excessively, unplug the
charger periodically.
Running engines produce heat. 4. With the battery fully charged, check the
Severe burns can occur on contact.
specific gravity readings of each cell with a
temperature-compensated Battery
• Allow muffler, engine cylinder fins, and radiator
Hydrometer (Figure 1-5). All readings
to cool before touching.
• Remove accumulated combustibles from muf- should be above 1.250 (compensating for
fler area and cylinder area. temperature). If the readings vary by
0.050 or if all cells read less than 1.225,
replace the battery.
Dirt or debris can restrict air flow and cause the
engine to overheat, resulting in poor
performance and reduced engine life. Continued
operation with a clogged cooling system can
cause severe overheating and possible engine
damage. Clean these areas (A, Figure 1-4)
yearly or more often when dust or airborne
debris is present.
Figure 1 - 5
ENGINE ADJUSTMENTS
Figure 1 - 6
Governor Adjustments
A complete governor system adjustment
includes a static adjustment, engine warm-up,
and top no-load adjustment. Be sure to complete
all steps.
Static Adjustment
1. Loosen nut (A, Figure 1-7) until governor
lever (B) moves freely from governor
crank (C).
2. Move throttle linkage (D) until throttle plate
(E) is wide open.
10
Figure 1 - 8
Figure 1 - 7
11
Figure 1 - 10
Figure 1 - 9
12
Figure 1 - 11
13
Figure 1 - 12
14
Figure 1 - 13
15
Figure 1 - 14
16
SYSTEMS CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
CHECK IGNITION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
CHECK CARBURETION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
CHECK COMPRESSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
ELECTRICAL SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
2
EQUIPMENT USED FOR TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 1
ALTERNATOR TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
BATTERY TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
17
Vibration
• Bent cutter blades
• Loose spindles and couplings
• Bent/broken deck or weldments
• Bent crankshaft
• Loose equipment mounting bolts Figure 2 - 1
• Damaged or worn belts and pulleys Engine Running
• Out of balance impeller If engine runs but misses during operation, a
quick check to determine whether the ignition is
Power Loss at fault can be made by installing Ignition Tester
• Bind or drag in moving parts of #19368 between the spark plug lead and spark
equipment plug (Figure 2-2). If spark is good but engine
• Grass build-up under deck misses, install a new spark plug.
• No lubrication in equipment gear box
• Excessive belt tension
18
3) Check Compression
Use Leakdown Tester #19545 to check the
sealing capabilities of the compression
2
Figure 2 - 2
components.
Follow the instructions provided with the tester to
1
If spark does not occur, look for: perform the leakdown test.
• Improperly operating interlock system
• Shorted equipment or engine stop switch NOTE: Any air leaks at the connections or
wire fittings of the tester will affect the accuracy of the
test.
• Incorrect armature air gap
• Armature failure
Listen for air leaking from the cylinder head
gasket, carburetor, exhaust system, and the
2) Check Carburetion crankcase breather tube.
Before making a carburetion check, be sure the • Air flowing between the cylinder and
fuel tank has an ample supply of fresh, clean cylinder head indicates that the cylinder
gasoline. head gasket is leaking.
Be sure the shutoff valve, if equipped, is open • Air flowing from the carburetor indicates
and fuel flows freely through the fuel line. If fuel air is leaking past the intake valve and
fails to flow or is slow, check for plugged fuel cap seat.
vent, fuel line restriction or plugged fuel filter. • Air flowing from the exhaust system
Be sure throttle and choke controls are properly indicates air is leaking past the exhaust
adjusted. valve and seat.
If engine cranks but will not start, remove and • Air flowing from the crankcase breather
inspect the spark plug. tube or high oil fill dipstick tube indicates
air is leaking past the piston rings.
If plug is wet, look for:
• Over choking
• Excessively rich fuel mixture Possible Causes for Poor Compression:
• Water in fuel • Loose cylinder head bolts
• Float needle valve stuck open • Blown head gasket
• Plugged air cleaner • Burned valves, valve seats and/or loose
valve seats
• Fouled spark plug
• Insufficient tappet clearance
If plug is dry, look for:
• Warped cylinder head
• Leaking carburetor or intake manifold
gaskets • Warped valve stems
• Gummy or dirty carburetor, fuel filter, fuel • Worn bore and/or rings
lines or fuel tank • Broken connecting rod
• Float needle valve stuck closed
• Inoperative fuel pump (if equipped)
• Inoperative fuel shut off solenoid (if
equipped)
19
DC Shunt
The Fluke® meter will withstand DC input of 10-
20 amps for up to 30 seconds.
The UNI-T® meter will withstand DC input of 10
amps for up to 10 seconds.
When checking DC output on 10 and 16 amp
regulated systems, the DC Shunt #19468
(Figure 2-3) is required to avoid blowing a fuse in
either of the meters.
Figure 2 - 5
Other Equipment
A growler or armature tester (checks armature
Figure 2 - 3 for continuity, shorts, and opens) is available
from an Automobile Diagnostic Service supplier.
Tachometer Also, a known good 12 Volt battery is required
Tachometers #19200 (A) or #19389 (B, Figure 2- when testing starting systems or alternators.
4) are available from your Briggs & Stratton
source of supply.
20
21
battery
The starter motor clutch is designed to prevent
• Faulty electrical connection (battery damage from shock loads such as engine
circuit) backfire. If the clutch slips while cranking,
• Dirty or worn starter motor commutator, replace the entire starter drive assembly.
bearing, weak magnets, etc.
• Wrong engine oil viscosity for ambient
Test Starter Motor
temperatures
1. Clamp starter motor test fixture in vise
• Defective starter clutch
(Figure2-8).
• Flywheel brake misadjusted
2. Remove starter motor from engine and
• Battery leads too long or wire diameter mount to fixture.
too small
2. Engine Will Not Crank NOTICE: Do not clamp the motor housing in a
• Improperly operating interlock system vise or strike with a hammer. Starter motors
• Discharged battery contain ceramic magnets that can be damaged if
• Loose or corroded electrical connections the motor housing is hit, deformed, or dented.
• Open circuit in starter motor switch
3. Set meter to DC Amps position.
• Open circuit in starter motor
4. Connect the optional starter switch
• Brushes sticking
(A, Figure 2-8), starter motor, battery (F),
• Inoperative starter solenoid black lead (C), red lead (D), shunt (E), and
• Blown fuse in equipment wiring harness tachometer (B).
3. Starter Motor Spins But Does Not Crank
Engine
• Sticking pinion gear
• Damaged pinion or ring gear
• Starter motor clutch slipping
• Incorrect rotation due to reversed motor
polarity
Figure 2 - 8
22
23
Testing Battery
1. With the battery fully charged, check the
specific gravity readings of each cell with a
temperature-compensated Battery
Hydrometer (Figure 2-9). All readings
should be above 1.250 (compensating for
temperature). If the readings vary by
0.050 or if all cells read less than 1.225,
replace the battery.
Figure 2 - 9
24
1
3
25
1
3
Figure 3 - 1
26
27
28
CARBURETOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32
29
Figure 4 - 1
30
•
area.
Do not overfill fuel tank. To allow for expansion
spacers at top and bottom of tank then lift
tank off engine.
4
of the gasoline, do not fill above the bottom of
the fuel tank neck. Inspection
• Keep gasoline away from sparks, open flames, 1. Clean gummy or dirty fuel tanks with
pilot lights, heat and other ignition sources. Briggs & Stratton Carburetor Cleaner
• Check fuel lines, tank, cap, and fittings fre- #100041 or #100042, or equivalent.
quently for cracks or leaks. Replace if neces-
2. Inspect fuel tank for:
4
sary.
• If fuel spills, wait until it evaporates before • Corrosion
starting engine.
• Leaks
When starting engine:
• Make sure spark plug, muffler, fuel cap, and air • Broken mounting brackets
cleaner are in place. 3. Check fuel cap and filler neck for:
• Do not crank engine with spark plug removed.
• Proper seals
• If fuel spills, wait until it evaporates before
starting engine. • Vents
• If engine floods, set choke (if equipped) to
OPEN/RUN position. Place throttle (if
Clean or replace parts as required.
equipped) in FAST and crank until engine
starts.
When operating equipment:
• Do not tip engine or equipment at an angle
Installation
which would cause fuel to spill. 1. Install fuel hose to tank fitting and secure
• Do not choke carburetor to stop engine. with hose clamp. Position tank on engine
• Never start or run the engine with the air and install screws, washers, and spacers
cleaner assembly (if equipped) or the air filter at top and bottom of tank. Torque screws
(if equipped) removed. to values in Section 12 - Engine
When changing oil:
Specifications.
• If you drain the oil from the top oil fill tube, the
fuel tank must be empty or fuel can leak out 2. Install trim cover and blower housing
and result in a fire or explosion. assembly.
When transporting equipment: 3. Install static guard/rewind assembly.
• Transport with fuel tank empty or with fuel shut- Torque screws to values listed in Section
off valve set to OFF.
12 - Engine Specifications.
When storing gasoline or equipment with fuel in
the tank: 4. Install gas cap and air cleaner cover.
• Store away from furnaces, stoves, water heat- 5. Partially fill tank with fuel and check for
ers, or other appliances that have a pilot light leaks. Repair as necessary.
or other ignition source because they can
ignite gasoline vapors.
31
Figure 4 - 2
32
33
34
35
Figure 5 - 1
36
Disassemble
1. Drain oil from engine into an appropriate
container.
2. Remove burrs and clean the crankshaft
PTO, the carefully remove sump from
engine and discard the gasket.
3. Loosen the governor lever nut and slide
the lever off the governor crank and
4
disconnect from the governor link. Set
aside.
4. Remove push nut or clip and washer (C)
Figure 5 - 2 from governor crank. Remove burrs and
clean the governor crank, then remove
crank from inside of cylinder.
Top No-Load RPM
Briggs & Stratton supplies engines with an
NOTE: Inspect governor gear for worn weight
pins and chipped or missing gear teeth before
5
adjustable top no-load RPM, which the
removing. Any time the governor gear is
equipment manufacturers set to their own
removed, it must be discarded and replaced with
specifications. Do not exceed these limitations.
a brand new governor gear.
37
38
DISASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41
INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41
ASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41
39
Figure 6 - 1
40
Inspection
1. Visually inspect cylinder head for cracks,
excessive heat discoloration, warping, and
burned or damaged valve seats. Replace
head, if any of these problems are found.
2. Inspect valves for wear or damage.
Replace if necessary.
3. Oil the intake valve stem then insert valve
into head.
4. Using Valve Lapping Tool #19258 and
Lapping Compound #94150, lap valve and
seat together to assure a good sealing
surface. Remove valve, then repeat
procedure for the exhaust valve.
5. Thoroughly clean both valves and valve
seats of all lapping compound residue.
41
42
REPLACE ROPE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
43
Figure 7 - 1
44
45
Figure 7 - 2
46
Replace Rope
Figure 7 - 6
Figure 7 - 4
47
48
BREATHER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51
49
Figure 8 - 1
50
Remove Breather
1. Remove breather tube (E) from breather
cover (F).
2. Remove two screws (G), breather cover,
and gasket. Discard gasket.
Check Breather
1. Remove and check breather reed (H). If
the reed is worn or bent it cannot function
properly and must be replaced.
2. Inspect the oil-drain back hole in the
breather cavity. Insert a fine wire to ensure
the opening is not plugged.
8
Install Breather
1. Install reed with the metal tab facing away
from the crankshaft. Torque screw to
value listed in Section 12 - Engine
Specifications.
2. Using new gasket, install breather cover
and torque screws to values listed in
Section 12 - Engine Specifications.
3. Securely install breather tube in breather
cover.
51
52
53
Figure 9 - 1
54
55
Cleaning Sump
1. Wash the sump thoroughly with kerosene
or other commercial solvent.
2. Wash sump again using a stiff brush with
soap and hot water.
3. Rinse sump thoroughly with hot running
4 water.
4. Repeat washing and rinsing until all traces
of oil sludge are gone.
Main Bearings
Figure 9 - 2
Plain Bearings
Sump
Plain (or machined) bearings are not repairable.
Press in new oil seal to a depth of 0.157 - 0.276
If a plain bearing is scored or worn beyond reject
in. (4 - 7 mm) (Figure 9-3).
its size, the cylinder or cover/sump must be
replaced.
DP™Bearings
DP™ bearings are not repairable. If a DP™
bearing is scored or worn beyond its reject size,
the cylinder or cover/sump must be replaced.
56
CRANKSHAFT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -58
10
57
10
Figure 10 - 1
58
Install Crankshaft
1. Lubricate the magneto bearing/oil seal
with engine oil.
2. Support both ends of the crankshaft, and
carefully install into the cylinder. 10
3. Rotate crankshaft until crankpin journal fits
into connecting rod.
4. Lubricate the crankpin journal with engine
oil, then assemble connecting rod to
crankshaft and torque cap screws to
values listed in Section 12 - Engine
Specifications.
NOTE: The screw closer to the piston must be
tightened first.
5. Install the timing gear to the crankshaft.
6. Align timing marks on timing gear and cam
gear (D), then install cam gear on boss in
cylinder.
59
10
60
DISASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63
INSPECT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63
ASSEMBLE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64
4
11
61
11
Figure 11 - 1
62
63
11
Figure 11 - 3
64
11
65
11
66
12
67
MODEL 090600
ENGINE SPECIFICATIONS
Alternator Air Gap .006 - .014 in. (.15 - .33 mm)
Armature Air Gap .006 - .014 in. (.15 - .33 mm)
Crankshaft End Play .002 - .038 in. (.05 - .97 mm)
Spark Plug Gap .020 in. (.51 mm)
Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm)
Valve Clearance – Exhaust .014 - .016 in. (.36 - .41 mm)
12
68
12
69
ENGINE SPECIFICATIONS
Alternator Air Gap .006 - .014 in. (.15 - .33 mm)
Armature Air Gap .006 - .014 in. (.15 - .33 mm)
Crankshaft End Play .002 - .038 in. (.05 - .97 mm)
Spark Plug Gap .020 in. (.51 mm)
Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm)
Valve Clearance – Exhaust .014 - .016 in. (.36 - .41 mm)
12
70
12
71
ENGINE SPECIFICATIONS
Alternator Air Gap .006 - .014 in. (.15 - .33 mm)
Armature Air Gap .006 - .014 in. (.15 - .33 mm)
Crankshaft End Play .002 - .038 in. (.05 - .97 mm)
Spark Plug Gap .020 in. (.51 mm)
Valve Clearance – Intake .004 - .006 in. (.10 - .15 mm)
Valve Clearance – Exhaust .014 - .016 in. (.36 - .41 mm)
12
72
12
73
74